Foam projectile with suction cup tip

ABSTRACT

A toy projectile includes a generally tubular first cylinder having an inner surface and an outer surface, and an integral second cylinder. The integral second cylinder includes a first end having a suction cup and a generally tubular second end having an inner surface and an outer surface. The outer surface of the second end of the second cylinder contacts the inner surface of the first cylinder.

TECHNICAL FIELD

The present disclosure relates generally to foam projectiles and, moreparticularly, to foam darts having a foam exterior cylinder and aninterior cylinder that is integrally formed with a suction cup and amethod of testing the same.

BACKGROUND OF THE DISCLOSURE

Darts for use with toys such as toy guns, toy bows, and the like, areknow in the art. For example, U.S. Pat. No. 5,186,156 discloses an airoperated toy gun adapted to propel a projectile. The projectile has ashaft with an enlarged head at a forward end of the shaft. A rearwardend of the shaft rests at a rearward end of a barrel at a section of apassageway having a reduced diameter relative to the more forwardportion of the passageway. The rearward end of the shaft has a circulartransverse cross section of a diameter which yields a snug and generallyairtight fit within the reduced diameter section. Another reduceddiameter section of the passageway serves to prevent the rearward end ofthe shaft from exiting a rearward opening of the barrel.

In another example, U.S. Pat. No. 5,535,729 discloses a projectilelauncher for launching projectiles. The projectiles are of conventionalconstruction and they preferably each include a generally cylindricalbody portion and a suction cup tip portion. Each of the body portionshas a rearwardly opening tubular recess formed therein which is adaptedto be received over a receiving tube, and each of the cylindricalportions is dimensioned to be received in a launching chamber.

SUMMARY OF THE DISCLOSURE

In accordance with one aspect of the disclosure, a toy projectile isdisclosed. The toy projectile includes a generally tubular firstcylinder having an inner surface and an outer surface, and an integralsecond cylinder having a first end and a generally tubular second endhaving an inner surface and an outer surface. The outer surface of thesecond end of the second cylinder contacts the inner surface of thefirst cylinder.

In accordance with another aspect of the disclosure, a toy projectile isdisclosed. The toy projectile includes an inner cylinder, and a tipportion integrally formed with the inner cylinder and disposed at afirst end of the inner cylinder.

In accordance with another aspect of the disclosure, a toy projectile isdisclosed. The toy projectile includes a generally cylindrical outercylinder having a first end and a second end, and an insert at leastpartially disposed in the outer cylinder. The insert includes a suctioncup at a first end and an elongate cylindrical section at a second end.The elongate cylindrical section has a generally constant outer diameterfrom the first end to the second end of the outer cylinder, when theouter cylinder and the insert are engaged.

In accordance with another aspect of the disclosure, a method of safetytesting a toy projectile is disclosed. The method includes providing aninner cylinder having disposed thereon an outer cylinder, the inner andouter cylinder having first and second ends, and fixedly attaching oneof the first and second ends of the toy projectile. The method furtherincludes pulling the other of the first and second ends of the toyprojectile to a specified force, and separating the outer cylinder intoat least two pieces, such that a first portion of the outer cylinderremains attached to the inner cylinder and a second portion of the outercylinder is detached from the inner cylinder.

These and other aspects and features of the disclosure will be morereadily understood upon reading the following detailed description whentaken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of a projectile according to one embodimentof the disclosure;

FIG. 2 is a side view with hidden lines of the separate parts of theprojectile of FIG. 1; and

FIG. 3 is cross sectional view along line 3-3 of the projectile of FIG.1;

FIG. 4 is cross sectional view of an alternate embodiment of theprojectile of FIG. 1 similar to FIG. 3; and

FIG. 5 is an isometric view of the projectile of FIG. 1 during a tensiontest.

DETAILED DESCRIPTION

Although the following text sets forth a detailed description ofnumerous different embodiments of the invention, it should be understoodthat the legal scope of the invention is defined by the words of theclaims set forth in the appended claims. The detailed description is tobe construed as exemplary only and does not describe every possibleembodiment of the invention since describing every possible embodimentwould be impractical, if not impossible. Numerous alternativeembodiments could be implemented, using either current technology ortechnology developed after the filing date of this patent, which wouldstill fall within the scope of the claims defining the invention.

It should also be understood that, unless a term is expressly defined inthis patent using the sentence “As used herein, the term ‘______’ ishereby defined to mean . . . ” or a similar sentence, there is no intentto limit the meaning of that term, either expressly or by implication,beyond its plain or ordinary meaning, and such term should not beinterpreted to be limited in scope based on any statement made in anysection of this patent (other than the language of the claims). To theextent that any term recited in the claims at the end of this patent isreferred to in this patent in a manner consistent with a single meaning,that is done for sake of clarity only so as to not confuse the reader,and it is not intended that such claim term by limited, by implicationor otherwise, to that single meaning. Finally, unless a claim element isdefined by reciting the word “means” and a function without the recitalof any structure, it is not intended that the scope of any claim elementbe interpreted based on the application of 35 U.S.C. § 112, sixthparagraph.

Referring now to the drawings, and with specific reference to FIG. 1, atoy projectile constructed in accordance with the teachings of thedisclosure is generally depicted by reference numeral 20. As showntherein, the projectile 20, in this exemplary embodiment, includes afirst or outer cylinder 22 and a second or inner cylinder 24. The toyprojectile 20, as disclosed herein, is intended to be used as a dart,arrow, bullet, or other projectile being shot or propelled from a toycompressed air projectile launcher, such as a toy gun, toy bow, and thelike. If, by chance, first and second cylinders come apart due to wear,improper handling, etc. the first and second cylinders 22, 24 may besized so as not pose a chocking hazard to children.

The outer cylinder 22, as seen in FIG. 2, may be constructed from alightweight foam material, but may be constructed from any other type ofresilient lightweight material that may be engaged by an inner surfaceof a barrel of a toy projectile launcher (not show). The outer cylinder22 has a generally tubular shape including an inner surface 26, an outersurface 28, a front end 30 and a back end 32. A front edge 34 disposednear the front end 30 of the outer cylinder 22 and a back edge 36disposed near the back end 32 of the outer cylinder 22, are orientedgenerally parallel to each other and generally perpendicular to alongitudinal axis of the outer cylinder 22.

The inner cylinder 24, as seen in FIG. 2, may be constructed from alightweight plastic or elastomeric material, but may be constructed fromany other type of semi-rigid to resilient lightweight material. A rearportion 44 of the inner cylinder 24 has a generally tubular shapeincluding an inner surface 37, an outer surface 56, a front portion 38and the rear portion 39. The front or tip portion 38 may be integrallyformed with the inner cylinder 24 proximate a front end of the rearportion 44 and may include a suction cup 40 having an open end extendingoutwardly from front end 42 of the rear portion 44. The suction cup 40may have a frustro-conical shape, and may be adapted to temporary adhereto a generally flat surface once pressed upon, such that the projectile20 may stick to a wall, door, window, and the like, during use.

A flange 46 may be disposed proximate intersection of 40 and 44, and maybe adapted to engage the front edge 34 of the outer cylinder 22 when theouter cylinder 22 is disposed on the inner cylinder 24. Morespecifically, as seen in FIG. 3, the front edge 34 of the outer cylinder22 may abut a rear surface 48 of the flange 46, thereby stopping orretaining the outer cylinder 22. The flange 46 may extend radiallyoutward from a center axis of the inner cylinder 24, and may include askirt 50 extending from a periphery thereof. An outer diameter of theflange 46 may be greater than an outer diameter of the inner cylinder 22so the front edge 34 may be disposed within the skirt 50. The skirt 50,as best seen in FIG. 3, may extent rearwardly, or toward the rearportion 44 of the inner cylinder 24, from the periphery of the flange46, thereby creating an annular groove 52 (FIG. 2) between the skirt 50and the elongate member rear portion 44 of the inner cylinder 24 forretaining or receiving the front end 30 of the outer cylinder 22. Theouter surface 56 of the inner cylinder 24 may frictionally engage theinner surface 26 of the outer cylinder 22, or may have glue, epoxy, orother adhesive retentively connecting the inner and outer cylinders 24,22.

As such, the inner and outer cylinders 24, 22 in combination andseparately are sized and/or shaped to meet safety specification, such asfor example, chocking hazard specifications set by one or more domesticand international governmental agencies. For example, one of the testingmethods, as partially shown in FIG. 5, is a tension test that pulls theprojectile 20 apart to a specified force. In one such tension test theprojectile 20 is fixedly attached at one end, such as the tip portion38, and is then pulled by the outer cylinder 22 until a force of 20 lbfor 88.9N or 88.9 kg*m/sˆ2 is reached or until the projectile 20 or thefoam cylinder 22 breaks. The chocking hazard specifications may furtherrequire that the individual pieces of the projectile 20 before and afterthe tension test meet a size or length requirement. The specification,for example, may require that the one or more pieces of the projectile20 be each at least 2 inches or 5.08 cm long or longer. Therefore, asseen in FIG. 5, the projectile 20 and, more specifically, the outer foamcylinder 22 may break into two separate pieces, but may both meet thechocking hazard specifications as the pieces broken-off piece and thepiece still attached to and in combination with the inner cylinder 24,as seen in FIG. 5, may still each be large enough.

The projectile 20 referenced throughout and the parts thereof may alsoinclude variations and/or additions. For example, the outer cylinder 22may be constructed from a number of materials, including but not limitedto, plastic, rubber, fabric, composites, and/or a combination thereof.The shape and size of the projectile 20, including the inner and outercylinders 24, 22 may also vary depending on the application andstructure of the toy (not shown) launching the projectile 20. The innerand outer cylinders 24, 22 may have a generally triangular, square,rectangular, or odd shaped cross-section, and may include additionaland/or alternate features. For example, the projectile 20 may includefins (not shown) protruding from the back end of the outer cylinder 22,or may include a rod or post (not shown) extending from the rear portion44. The rear portion 44 may also have a solid or otherwise filled cavity54. The inner and outer cylinders 24, 22 may also be reversed, as seenin FIG. 4, wherein the inner cylinder 22 may include an outercylindrical portion 51 extending from the skirt 50, and may or may notinclude the rear portion 44 of the inner cylinder 24. Similarly, thetension test specifications may be more or less than 20 lbf, and the andthe size or length requirement may be more or less than 2 inches or 5.08cm.

In operation, the toy projectile 20 may be used as a projectile beingshot or propelled from a toy, such as a toy gun, toy bow, and the like(not shown). The user may connect the inner and outer cylinders 24, 22of the projectile 20 by sliding the outer cylinder 22 over the innercylinder 24 and, more specifically, by sliding the outer cylinder 22over the inner cylinder 24 such that the inner surface 26 of the outercylinder abuts an outer surface 56 at the inner cylinder 24 and thefront end 30 of the outer cylinder engages the annular groove 52. In theconnected position, the inner surface 26 of the outer cylinder may abuta majority of the outer surface 56 of the inner cylinder 24 and, as inthis exemplary embodiment, the inner surface 26 of the outer cylindermay abut the entire outer surface 56 of the inner cylinder 24. In theconnected position, the front surface 34 of the outer cylinder 22 mayalso abut the rear surface 48 of the flange 46.

While the present invention has been described with reference tospecific examples, which are intended to be illustrative only and not tobe limiting of the invention, it will be apparent to those of ordinaryskill in the art that changes, additions or deletions may be made to thedisclosed embodiments without departing from the spirit and scope of theinvention.

1. A toy projectile, comprising: a generally tubular first cylinderhaving an inner surface and an outer surface; and an integral secondcylinder having a first end and a generally tubular second end having aninner surface and an outer surface, wherein the outer surface of thesecond end of the second cylinder contacts the inner surface of thefirst cylinder.
 2. The toy projectile of claim 1, wherein a majority ofthe outer surface of the second end of the second cylinder contacts theinner surface of the first cylinder.
 3. The toy projectile of claim 1,wherein the first end includes a suction cup.
 4. The toy projectile ofclaim 1, wherein the first cylinder is constructed from a lightweightfoam material.
 5. The toy projectile of claim 1, wherein the secondcylinder is constructed from a plastic material.
 6. The toy projectileof claim 1, wherein the second end of the second cylinder issubstantially flush with a second end of the first cylinder.
 7. The toyprojectile of claim 1, wherein the second end of the second cylinder ishollow.
 8. The toy projectile of claim 1, further including a flangeextending radially outward between the first and second ends of thesecond cylinder, the flange being adapted to contact a first end of thefirst cylinder.
 9. The toy projectile of claim 8, further including askirt extending rearwardly from a periphery of the flange, such that aninner surface of the skirt contacts the outer surface of the firstcylinder.
 10. The toy projectile of claim 1, wherein the first andsecond cylinders are each at least 2 inches long.
 11. A toy projectile,comprising: an inner cylinder; and a tip portion integrally formed withthe inner cylinder and disposed at a first end of the inner cylinder.12. The toy projectile of claim 11, further including an outer cylinderdisposed on the inner cylinder.
 13. The toy projectile of claim 12,wherein the inner cylinder includes an outer surface the majority ofwhich contacts an inner surface of the outer cylinder.
 14. The toyprojectile of claim 11, wherein the tip portion includes a suction cup.15. The toy projectile of claim 12, wherein the outer cylinder isconstructed from a lightweight foam material.
 16. The toy projectile ofclaim 11, wherein the inner cylinder is constructed from a plasticmaterial.
 17. The toy projectile of claim 11, wherein the inner cylinderis hollow.
 18. The toy projectile of claim 11, further including aflange extending radially outward from the inner cylinder.
 19. The toyprojectile of claim 18, further including a skirt extending rearwardlyfrom a periphery of the flange.
 20. The toy projectile of claim 12,wherein the inner and outer cylinders are each at least 2 inches long.21. A toy projectile, comprising: a generally cylindrical outer cylinderhaving a first end and a second end; and an insert at least partiallydisposed in the outer cylinder, the insert having a suction cup at afirst end and an elongate cylindrical section at a second end, whereinthe elongate cylindrical section has a generally constant outer diameterfrom the first end to the second end of the outer cylinder, when theouter cylinder and the insert are engaged.
 22. The toy projectile ofclaim 21, wherein the outer cylinder is constructed from a lightweightfoam material.
 23. The toy projectile of claim 21, wherein the insert isconstructed from a plastic material.
 24. The toy projectile of claim 21,wherein the elongate cylindrical section is hollow.
 25. The toyprojectile of claim 21, further including a flange extending radiallyoutward between the first and second ends of the insert, the flangebeing adapted to contact the first end of the outer cylinder.
 26. Thetoy projectile of claim 25, further including a rim extending rearwardlyfrom an outer edge of the flange, such that an inner surface of the rimcontacts an outer surface of the first cylinder.
 27. A method of safetytesting a toy projectile comprising: providing an inner cylinder havingdisposed thereon an outer cylinder, the inner and outer cylinder havingfirst and second ends; fixedly attaching one of the first and secondends of the toy projectile; pulling the other of the first and secondends of the toy projectile to a specified force; and separating theouter cylinder into at least two pieces, such that a first portion ofthe outer cylinder remains attached to the inner cylinder and a secondportion of the outer cylinder is detached from the inner cylinder.